Take one front bumper cover from an 82-84 T/A and a front bumper cover from an 86 T/A with the fog lights and mix them together and you have the front bumper cover I am working on building. I will also be building a custom air scoop. (not a hood scoop but making it a scoop instead of a flap air dam so it collects more air and forces it in rather than creating a low pressure area.) I will also be trimming away the front bumper support where the front grilles sit so the air will going directly over the radiator and air condensor coil. at low speeds there won't be much of a difference but at high speeds the cooling capabillatity should be increased. I will post pictures and keep people updated on the progress.

 

A question has come to my attention. There are two methods I can go about for doing this custom work. I can either use a plastic welder or I can use an epoxy like the 3M Automix... Which would you guys recommend using? I am going to have to use pinning holes for sure. And what kind of polyurethane did they use on those bumper covers? Was it Thermoset Polyurethane or was it Thermoplastic Polyurethane? There is going to be a large area that needs either epoxy or welding. I am wondering which will give me more structural integrity so my bumper doesn't fall apart going down the road.

 

Make a mold of each of the parts you want and build it out of fiberglass.

 

The problem with the idea of fiberglass is that fiberglass does not flex. When fiberglass flexes it will crack and which is why I couldn't use fiberglass to mount to the polyurethane. The polyurethane will flex and the pieces that I tried to mount will fall off. The only way to have the fiberglass work is to build a frame ( very simillar to how rebar is used in concrete.) The degree of difficulty is increased dramaticly when building a frame is required. There are a lot of contours on the front bumper cover that would be extremely hard to replicate. Sadly Fbodies are unibodies which does make them lighter but the whole car flexes. My knowledge is limited but based off my research and previous experience with fiberglass it would seem to me that the polyurethane would be easier to work with than the fiberglass. Also it seems that the polyurethane holds up better to abuse than fiberglass (ie. rocks ect.)

 

Sounds like a good idea. I like the panels/grills in the 82-84 cover, and the fog lights of the later ones. I look forward to seeing the finished product.

 

Are you planning to crash the car? If not use the glass.
It may take a bit of time to perfect the mold but if you do destroy it, you could make another easily.
Make the nose all out of fiberglass, don't try and glue rubber to the glass (thats not what I was saying to do). That will be your best bet. If you bump something with the rubber nose your trying to glue together, you won't be much better off.
Fiberglass will be better for top speeds also.

Read this
http://www.pasincorporated.com/turbo...ject/id-2.html

And this
http://www.pasincorporated.com/turbo...ject/id-5.html